Fuel cell

ABSTRACT

An example fuel cell assembly may include a proton exchange membrane (or membrane electrode assembly) that has a first major surface and a second major surface. An anode electrode, which may include a patterned metal layer with a plurality of apertures extending through the patterned metal layer, may also be provided. An anode gas diffusion layer secured to an anode adhesive frame may be situated between the anode electrode and the first major surface of the proton exchange membrane. A cathode electrode may, in some instances, include a patterned metal layer with a plurality of apertures extending through the patterned metal layer. A cathode gas diffusion layer secured to a cathode adhesive frame may be situated between the cathode electrode and the second major surface of the proton exchange membrane. In some instances a fuel cell assembly may be flexible so that the fuel cell assembly can be rolled into a rolled configuration that defines an inner cavity with open ends. A fuel pellet may be inserted into the inner cavity, and one or more end caps may be provided to cover and seal the open ends.

PRIORITY

This application is a continuation-in-part of U.S. patent application Ser. No. 12/335,352 entitled “Metal Hydride Fuel Cell Power Generator”, the entire disclosure of which is herein incorporated by reference.

TECHNICAL FIELD

The present disclosure relates generally to fuel cells, and more particularly, to fuel cells and/or components thereof, as well as methods of making fuel cells.

BACKGROUND

A wide variety of fuel cells have been developed. Of the known fuel cells, each has certain advantages and disadvantages. There is an ongoing need to provide alternative fuel cells.

SUMMARY

The disclosure relates generally to fuel cells, and more particularly, to fuel cells and/or components thereof, as well as methods of making fuel cells. An example fuel cell assembly may include a proton exchange membrane (or membrane electrode assembly) that has a first major surface and a second major surface. An anode electrode, which may include a patterned metal layer with a plurality of apertures extending through the patterned metal layer, may also be provided. An anode gas diffusion layer secured to an anode adhesive frame may be situated between the anode electrode and the first major surface of the proton exchange membrane. A cathode electrode may, in some instances, include a patterned metal layer with a plurality of apertures extending through the patterned metal layer. A cathode gas diffusion layer secured to a cathode adhesive frame may be situated between the cathode electrode and the second major surface of the proton exchange membrane. In some instances, the anode gas diffusion layer and the anode adhesive frame lie substantially in a common plane, but this is not required. Likewise, the cathode gas diffusion layer and the cathode adhesive frame may lie substantially in a common plane, but again this is not required.

In some instances, the resulting fuel cell assembly may be flexible so that the fuel cell assembly can be rolled into a rolled configuration that defines an inner cavity with open ends. In some cases, the rolled configuration may be a substantially cylindrical configuration. A fuel pellet may be inserted into the inner cavity, and one or more end caps may be provided to cover and seal the open ends.

The above summary is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The Figures and Description which follow more particularly exemplify various illustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following description of various illustrative embodiments in connection with the accompanying drawings, in which:

FIG. 1 is a top and side view of an example substrate for use in forming an illustrative fuel cell electrode;

FIG. 2 is a top and side view of an example insulting film on the substrate;

FIG. 3 is a top and side view of an example layer of metal on the insulating film;

FIG. 4 is a top and side view illustrating perforations in the structure shown in FIG. 3;

FIG. 5 is an example electrode;

FIG. 6 is an example layer disposed on the electrode;

FIG. 7 is another example layer disposed on the structure illustrated in FIG. 6;

FIG. 8 is another example layer disposed on the structure illustrated in FIG. 7;

FIG. 9 is another example electrode disposed on the structure illustrated in FIG. 8; and

FIG. 10 is an exploded view of an example fuel cell.

While this disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DESCRIPTION

The following description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the invention.

For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification.

All numeric values are herein assumed to be modified by the term “about,” whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the terms “about” may include numbers that are rounded to the nearest significant figure.

The recitation of numerical ranges by endpoints includes all numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

Fuel cells may be desirable, for example, because they may represent a commercially viable power source that offers a relatively high energy density and a relatively high power density. The use of fuel cell stacks, which may include assembling or stacking a number of layers to form a fuel cell stack assembly, may be important for the manufacturing of such viable fuel cells. For example, some fuel cell stack assemblies may be relatively inexpensive, thin, and flexible. As such, these fuel cell stack assemblies may be capable of being used in a wide variety of fuel cells, in a wide variety of different shapes (e.g., non-planar form factors) and applications. A fuel cell stack assembly may, for example, be rolled or otherwise formed into a desired shape and configured for a variety of uses.

Manufacturing a fuel cell may include a number of processes and/or processing steps. For example, FIGS. 1-4 show a number of illustrative steps for forming a fuel cell electrode. FIGS. 5-9 show an illustrative method of making a relatively planar fuel cell stack assembly. FIG. 10 shows an illustrative fuel cell assembly that has been rolled into a rolled configuration to form an inner cavity that may include a fuel pellet.

As shown in FIGS. 1-4, fabrication of an illustrative fuel cell electrode may, in some cases, begin with a substrate 10 as illustrated in FIG. 1. Substrate 10 may include a metal substrate. For example, substrate 10 may include nickel plated steel, stainless steel, a corrosion resistant metal, or any other suitable material, as desired. The form of substrate 10 may vary. For example, substrate 10 may include a generally planar sheet of material. In one example embodiment, substrate 10 may be about 0.001 to about 0.010 inches thick or so. Other sizes, shapes and/or thicknesses are contemplated.

In the illustrative method, a layer of material 12 may be disposed on substrate 10, as illustrated in FIG. 2. In at least some embodiments, material 12 may be an insulting and/or dielectric material. For example, material 12 may be polyimide or any other suitable dielectric material. In one example embodiment, material 12 may be about 1-10 μm thick or so. Other thicknesses are contemplated.

Next, and as shown in FIG. 3, a layer of metal 14 may be disposed on material 12. Metal 14 may take the form of a gold layer that is, for example, patterned on the surface of material 12 with a shadow mask. It is contemplated that other materials and/or methods may be used to dispose metal 14 on material 12.

Next, and as shown in FIG. 4, one or more of layers 10/12/14 may be perforated to create a plurality of apertures. The apertures may extend through layers 10, 12, and/or 14. Creating the apertures may include, for example, perforating layers 10, 12, and/or 14 with an appropriate cutting tool or die, using a cutting laser, using chemical etching, or using any other suitable method, as desired.

Perforations may form a perforated surface 16 that may include perforation of metal layer 14 (indicated in FIG. 4 with reference number 14′), perforation of material 12 (indicated in FIG. 4 with reference number 12′), perforation of substrate 10 (indicated in FIG. 4 with reference number 10′), or perforation of any combination of these structures. After perforation, the resultant structure may take the form of an electrode 18. Electrode 18 may also be trimmed or otherwise cut or altered, if desired, so as to have the desired shape or configuration. Such an electrode 18 may be used, for example, as a cathode or anode electrode for a fuel cell assembly, as desired.

The process of forming a fuel cell stack assembly may include “stacking” various layers including electrodes as well as appropriate layers and/or materials between the electrodes. FIGS. 5-9 show an illustrative method of making an illustrative relatively planar fuel cell stack assembly.

As shown in FIG. 5, an electrode 18 may be provided. In this example, electrode 18 may comprise an anode. However, in other examples electrode 18 may be a cathode. One or more layers may be disposed on or adjacent to electrode 18. For example, in FIG. 6, a gas diffusion layer 22 a and a layer of adhesive or adhesive frame 20 a may be disposed on or adjacent to electrode 18. In at least some embodiments, layers 20 a/22 a may lie substantially in the same plane as shown. Layer 22 a may be, for example, an anode gas diffusion layer. The material for gas diffusion layer 22 a may depend on the application, and in some cases, may include a conductive material, a porous electrically conductive material, a carbon fabric, or the like. Other materials are also contemplated.

In the example illustrated in FIG. 5, adhesive frame 20 a is generally disposed about the periphery and/or perimeter of gas diffusion layer 22 a. This allows adhesive 20 a to join with adhesive 20 c (discussed below) and effect a gas seal therebetween as discussed below. This arrangement, however, is not intended to be limiting as other patterns, configuration, and/or arrangements are contemplated. Such arrangements may include any suitable method such as, for example, coating, screening, screen printing, combinations thereof, and the like, or any other suitable process.

In some cases, a first major surface of a proton exchange membrane (PEM) (or membrane electrode assembly (MEA)) 24 may be disposed on or adjacent to layers 20 a/22 a, as shown in FIG. 7. The adhesive or adhesive frame 20 a discussed above may help secure the electrode 18, the gas diffusion layer 22 a and the membrane 24 together, and may further help form a gas seal therebetween. PEM 24 may include any suitable material such as, for example, a carbon and/or platinum coated ion-conductive material.

Another set of layers may be disposed on or adjacent a second major surface of the membrane 24. For example, FIG. 7 illustrates another gas diffusion layer 22 c and a layer of adhesive or adhesive frame 20 c disposed on or adjacent to the second major surface of the membrane 24. In at least some embodiments, layers 20 c/22 c may lie in the same plane. In some instances, layer 22 c may be a cathode gas diffusion layer and/or may include a carbon fabric or other suitable material. Layers 20 c/22 c may be similar in form and function to layers 20 a/22 a described above.

Another electrode 26 may be disposed on layers 20 c/22 c as shown in FIG. 8. In this example, electrode 26 may comprise a cathode. However, in other examples electrode 26 may be an anode. Like above, the adhesive or adhesive frame 20 c may help secure the electrode 26, the gas diffusion layer 22 c and the membrane 24 together, and may further help form a gas seal therebetween. In some instances, the various layers may be compressed such that the layers adhere together and form a single monolithic fuel cell assembly 28. In FIG. 9, the joining together of adhesive layers 20 a/20 c is shown to represent the bonding together of the various layers and the forming of a gas seal along the periphery of the single monolithic fuel cell assembly 28.

FIG. 10 shows a fuel cell assembly 30, illustrated in exploded view. Here it can be seen that a fuel cell assembly 28 may be rolled together into a rolled configuration that defines an inner cavity. In the illustrative embodiment, the edges, for example a first edge 32 a and a second edge 32 b of the fuel cell assembly 28 may be joined together via welding, adhesive, or in any other suitable manner. The rolled configuration may form an inner cavity in which a fuel source or pellet 36 may be disposed within. Fuel cell assembly 30 may also include one or more caps such as a first end cap 38 and a second end cap 40 to cover the open ends of the cavity.

In at least some embodiments, fuel source 36 may include a hydrogen source. For example, fuel source 36 may include a metal hydride. Such materials may be desirable, for example, because it may be possible to recharge these materials with hydrogen. Example metal hydrides may include LaNi₅H₅, FeTiH₂, Mg₂NiH₄, and TiV₂H₄. Example chemical hydrides include but are not limited to NaAlH₄, LiAlH₄, Mg(AlH₄)₂, Ti(AlH₄)₄, Fe(BH₄)₄, NaBH₄, and Ca(BH₄)₂. Other materials are also contemplated.

The resultant fuel cell assembly 30 may form a power source that may used to power a variety of electronic devices. In some instances, fuel cell assembly 30 may have a form factor that allows it to be manufactured as a suitable replacement for typical AA, AAA, C, D, 9-volt, or other batteries currently used. In addition, because fuel cell assembly 30 may utilize a metal hydride for fuel source 36, it may be rechargeable such that it can be recharged a relatively large number of times so that the total cost of the fuel cell assembly may be relatively low to the end user.

It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed 

1. A fuel cell assembly, comprising: a proton exchange membrane having a first major surface and a second major surface; an anode electrode, the anode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer; an anode gas diffusion layer with an anode adhesive frame, wherein the anode gas diffusion layer with the anode adhesive frame is situated between the anode electrode and the first major surface of the proton exchange membrane, wherein the anode gas diffusion layer and the anode adhesive frame lie substantially in a common plane; a cathode electrode, the cathode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer; and a cathode gas diffusion layer with a cathode adhesive frame, wherein the cathode gas diffusion layer with the cathode adhesive frame is situated between the cathode electrode and the second major surface of the proton exchange membrane, wherein the cathode gas diffusion layer and the cathode adhesive frame lie substantially in a common plane.
 2. The fuel cell assembly of claim 1, wherein: the fuel cell assembly is arranged in a rolled configuration to define an inner cavity; and a fuel pellet disposed in the cavity.
 3. The fuel cell assembly of claim 2, wherein the fuel cell assembly includes opposing edges, wherein when the fuel cell assembly is arranged in the rolled configuration, the two opposing edges of the fuel cell assembly are secured together to define the inner cavity.
 4. The fuel cell assembly of claim 3, further comprising end caps for covering each of the two open ends of the fuel cell assembly when the fuel cell assembly is arranged in the rolled configuration.
 5. The fuel cell assembly of claim 1, wherein the anode electrode includes a substrate, a dielectric layer on the substrate, and a patterned metal layer on the dielectric layer, wherein the plurality of apertures of the anode electrode extend through the patterned metal layer, the dielectric layer and the substrate.
 6. The fuel cell assembly of claim 5, wherein the substrate is a metal foil.
 7. The fuel cell assembly of claim 5, wherein the substrate extends beyond the pattern metal layer in at least one region of the anode electrode.
 8. The fuel cell assembly of claim 5, wherein the cathode electrode includes a substrate, a dielectric layer on the substrate, and a patterned metal layer on the dielectric layer, wherein the plurality of apertures of the cathode electrode extend through the patterned metal layer, the dielectric layer and the substrate.
 9. A method for forming a fuel cell stack, the method comprising: providing an anode electrode, the anode electrode including a plurality of apertures; disposing an anode gas diffusion layer adjacent the anode electrode, disposing a membrane electrode assembly adjacent the anode gas diffusion layer; disposing a cathode gas diffusion layer adjacent the membrane electrode assembly; providing a cathode electrode adjacent the cathode gas diffusion layer; and securing the anode electrode, anode gas diffusion layer, membrane electrode assembly, cathode gas diffusion layer and cathode electrode together to form a relatively planar fuel cell assembly having opposing edges; and rolling the fuel cell assembly into a rolled configuration to define an inner cavity.
 10. The method of claim 9, wherein when the fuel cell assembly is arranged in the rolled configuration, the two opposing edges of the fuel cell assembly are secured together to define the inner cavity.
 11. The method of claim 10, wherein the two opposing edges of the fuel cell assembly are secured together by a weld bond.
 12. The method of claim 10, wherein the two opposing edges of the fuel cell assembly are secured together by an adhesive bond.
 13. The method of claim 10, further comprising: installing end caps for covering each of two open ends of the fuel cell assembly when the fuel cell assembly is arranged in the rolled configuration.
 14. The method of claim 9 further comprising: inserting a fuel pellet into the cavity.
 15. The method of claim 9, wherein rolling the fuel cell assembly includes rolling the fuel cell assembly into a substantially cylindrical configuration.
 16. A fuel cell assembly, comprising: a proton exchange membrane having a first major surface and a second major surface; an anode electrode, the anode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer; an anode gas diffusion layer secured to an anode adhesive frame, wherein the anode gas diffusion layer and the anode adhesive frame are situated between the anode electrode and the first major surface of the proton exchange membrane; a cathode electrode, the cathode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer; a cathode gas diffusion layer secured to a cathode adhesive frame, wherein the cathode gas diffusion layer and the cathode adhesive frame are situated between the cathode electrode and the second major surface of the proton exchange membrane; wherein, the fuel cell assembly is arranged in a rolled configuration to define an inner cavity with open ends; and one or more end caps for covering the open ends.
 17. The fuel cell assembly of claim 16 further comprising a fuel pellet disposed in the inner cavity.
 18. The fuel cell assembly of claim 16, wherein when the fuel cell assembly is arranged in the rolled configuration, two opposing edges of the fuel cell assembly are secured together to define the inner cavity.
 19. The fuel cell assembly of claim 18, wherein the two opposing edges of the fuel cell assembly are secured together by a weld bond.
 20. The fuel cell assembly of claim 18, wherein the two opposing edges of the fuel cell assembly are secured together by an adhesive bond. 